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Abstract:

A ceiling panel uses a perimeter frame with a wide outwardly extending
bottom flange defining a thin panel edge. Preferably the bottom flange
includes a lower surface for securing of a finished substrate about the
panel perimeter. The upper surface of the bottom flange receives a gusset
clip that includes two arms for securement of the bottom flange and an
upwardly extending lift and shift securing tab. The upwardly extending
lift and shift securing tab is preferably located within a depth of the
ceiling panel generally defined by an acoustical dampening material
located within the perimeter frame.

Claims:

1. A ceiling panel comprising a perimeter frame, an acoustical insert
secured within said perimeter frame and inwardly offset from a side edge
of said ceiling panel, and a finished surface substrate secured beneath
and covering a lower surface of said perimeter frame and said acoustical
insert material; said perimeter frame comprising a series of connected
extruded members where each extruded member includes an outwardly
extending flange defining a wide border edge of said ceiling panel and an
integral vertical section to one side of said flange; and wherein said
finished surface substrate is secured to said outwardly extending flange
of each extruded member and said vertical section of each extruded member
is held in abutting contact with a side edge of said acoustical insert.

2. A ceiling panel as claimed in claim 1 wherein each extruded member
includes in cross section at least one securing flange extending inwardly
from said vertical section and located at an end of said vertical section
opposite said outwardly extending flange or at an intermediate position
on said vertical section.

3. A ceiling panel as claimed in claim 1 wherein each extruded member
includes two inwardly extending securing flanges positioned in a non
aligned manner with said outwardly extending flange.

4. A ceiling panel as claimed in claim 3 wherein one of said inwardly
extending flanges overlies a top edge of said acoustical insert.

5. A ceiling panel as claimed in claim 4 wherein one of said inwardly
extending flanges is received and projects into a side edge of said
acoustical insert.

6. A ceiling panel as claimed in claim 1 wherein a top surface of each
outwardly extending flange includes a low profile securing channel
extending in a length thereof.

7. A ceiling panel as claimed in claim 6 including gusset securing
brackets where each gusset securing bracket is received in the low
profile securing channels of abutting extruded members and secures said
abutting extruded members.

8. A ceiling panel as claimed in claim 7 wherein each gusset securing
bracket is generally made of `L` shaped stamped plate with at least one
upwardly and forwardly extending securing tab defining a securing gap
below said securing tab for supporting said ceiling panel from a `T` bar
grid.

9. A ceiling panel as claimed in claim 8 wherein each gusset securing
bracket includes a first flat arm without any significant protrusions on
an upper surface thereof and a second flat arm having said at least one
upwardly extending securing tab with a horizontal extending segment.

10. A ceiling panel as claimed in claim 9 wherein said at least one
upwardly and forwardly extending securing tab extends upwardly at an
intermediate position with respect to a width of said second flat arm.

11. A ceiling panel as claimed in 10 wherein said forwardly extending
securing tab includes a positioning notch.

12. A ceiling panel as claimed in 11 wherein each gusset securing bracket
includes at least one upwardly extending alignment tab in engagement with
said vertical section of said extrusion member.

13. A ceiling panel as claimed in claim 12 wherein said alignment tab is
located intermediately the width of said second arm and interiorly of the
securing tab.

14. A ceiling panel as claimed in claim 13 wherein said outwardly
extending flange on a bottom surface includes a series of longitudinally
extending shallow ribs of a progressively decreasing height from said
vertical section to said perimeter of said ceiling panel.

15. A ceiling panel as claimed in claim 11 wherein said series of shallow
ribs includes at least 3 shallow ribs.

16. A ceiling panel as claimed in claim 7 wherein said ceiling panel is
rectangular with 4 corners with gusset securing brackets in each corner
and wherein said gusset securing brackets include a first pair of
adjacent gusset securing brackets on two of said corners with said
horizontal extending segment orientated in a first direction and a second
pair of adjacent gusset securing brackets on the two remaining corners
with said horizontal extending segments orientated in a second direction
opposite to said first direction.

Description:

FIELD OF THE INVENTION

[0001] The present invention relates to suspended ceiling systems, and in
particular, to a ceiling panel having an enlarged perimeter flange for
securement beneath a "T" bar grid system, and a particular structure of
the ceiling panel.

BACKGROUND OF THE INVENTION

[0002] "T" bar ceiling systems are extremely well known and are primarily
used for receiving a fiber type ceiling panel that is supported above
outwardly extending flanges of the "T" bar grid system. With this
arrangement, the bottom flange of the "T" bar grid components is visible
from below and forms part of the finished ceiling surface. In most cases
the ceiling panels are generally planar and located above the bottom
flange. In some "T" bar ceiling systems the acoustical panels may be
contoured and partially extend below the "T" bar grid system while still
supported at the perimeter edge by the "T" bar grid members. This type of
arrangement reduces the visual effect of the exposed "T" bars but the
lower flanges continue to be visible.

[0003] It is also known to use a "T" bar grid system for suspending
ceiling panels below the grid system such that the ceiling panels hide
the "T" bar grid network (concealed "T" bar ceiling system). In these
systems the upper edge of the ceiling panels engage the lower flange of
the "T" bar grid network. Torsion springs or other securing arrangements
suspend the ceiling panels beneath the "T" bar grid system.

[0004] A lift and shift "T" bar grid ceiling panel system is known that
suspends ceiling panels beneath a "T" bar grid network. In some lift and
shift grid ceiling panel systems a portion of the grid network is exposed
and forms part of the finished ceiling system. Other lift and shift
ceiling panel systems are designed to overlap substantially on the lower
surface with the "T" bar members thus hiding the grid network. In this
type of system the acoustical panel is oversized relative to the cells of
the grid network. The ceiling panels are secured to the grid network by
initially suspending one edge of a panel and shifting it over relative to
the grid network. The panel may then be moved to the horizontal position
and shifted in the opposite direction to suspend the opposite edge of the
ceiling panel.

[0005] Although these systems in theory provide an accurate ceiling
(little variation in the plane of the ceiling), the known lift and shift
systems locate the ceiling panels below the grid network and the
suspension clips of each panel are mounted on a top surface of the panel.
To avoid or reduce possible damage the suspension clips are secured to
the panels on site by the installer. This is a time consuming process and
introduces a further variable that may affect the quality of the ceiling
system.

[0006] The present invention seeks to overcome a number of manufacturing
issues with respect to lift and shift suspended ceiling systems, and also
provides a system which is convenient to install.

SUMMARY OF THE INVENTION

[0007] A ceiling panel according to the present invention comprises a
perimeter frame, an acoustical insert secured within the perimeter frame,
and positioned to be inwardly offset to a side edge of the ceiling panel.
A finished surface substrate is secured beneath and covers a lower
surface of the perimeter frame and the acoustical insert material. The
perimeter frame comprises a series of connected extruded members where
each extruded member includes an outwardly extending flange defining a
wide border edge of the ceiling panel and an integral vertical section to
one side of the flange. The outwardly extending flange and the integral
vertical section collectively form a stepped side edge of the ceiling
panel. The finished surface substrate is secured to the outwardly
extending flange of each extruded member and the vertical section of each
extruded member is held in abutting contact with a side edge of the
acoustical insert.

[0008] In a preferred aspect of the invention, each extruded member
includes in cross section at least one securing flange extending inwardly
from the vertical section and located at an end of the vertical section
opposite the outwardly extending flange or at an intermediate position on
the vertical section.

[0009] In yet a further aspect of the invention each extruded member
includes two inwardly extending securing flanges positioned in a
non-aligned manner with the outwardly extending flange.

[0010] In yet a further aspect of the invention one of the inwardly
extending flanges overlies a top edge of the acoustical insert.

[0011] In a different aspect of the invention one of the inwardly
extending flanges is received and projects into a side edge of the
acoustical insert.

[0012] In a preferred aspect of the invention a top surface of each
outwardly extending flange includes a low profile securing channel
extending in a length of the extruded member. Preferably gusset securing
brackets are provided where each gusset securing bracket is received in
the low profile securing channels of abutting extruded members with these
gusset securing brackets connecting abutting extruded members.

[0013] In a further aspect of the invention, each gusset securing bracket
is generally an L-shaped stamped plate with at least one upwardly and
forwardly extending securing tab defining a securing gap below said
securing tab for supporting said ceiling panel from a "T" bar grid.

[0014] In yet a further aspect of the invention each gusset securing
bracket includes a first flat arm without any significant protrusions on
an upper surface thereof and a second flat arm having at least one
upwardly extending securing tab with a horizontal extending segment.

[0015] In yet a further aspect of the invention the outwardly extending
flange of each extruded member includes on a bottom surface thereof a
series of longitudinally extending shallow ribs of progressively
decreasing height from the vertical section to the perimeter of the
ceiling panel. Preferably these series of shallow ribs include at least
three shallow ribs.

[0016] In yet a further aspect of the invention the ceiling panels are
preferably rectangular in shape with gusset securing brackets provided in
each corner of the rectangular shaped ceiling panel.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Preferred embodiments of the invention are shown in the drawings,
wherein:

[0034] FIG. 17 is a perspective view of a modified suspension gusset clip;

[0035] FIG. 18 is a top view of the gusset clip of FIG. 17;

[0036] FIG. 19 is a side view of the modified gusset clip of FIG. 17; and

[0037] FIG. 20 is a partial perspective view of the modified gusset clip
installed at a corner of a ceiling panel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] The suspended ceiling system 2 includes the "T" bar support grid 4
with a series of suspended ceiling panels 6 secured to the underside of
the support grid. The support grid includes main T-members 8 and cross
T-members 10. Also shown in FIG. 1 is an "T"-member 12 which is L-shaped
to support a ceiling panel adjacent a vertical wall. As shown from the
perspective view of FIG. 1 looking upwardly, the ceiling panels 6
essentially hide the "T" bar support grid such that the "T" bar support
grid is not visible from below the ceiling panel. As more clearly shown
in the perspective view of FIG. 2, the ceiling panels 6 hide the bottom
flange of the main "T"-member 8.

[0039] The "T" bar support grid generally shown as 4 is extensively used
in ceiling systems, is relatively inexpensive and is well known to a host
of installers.

[0040] During installation, the main "T"-members 8 are appropriately
suspended beneath an unfinished ceiling.

[0041] Once the main "T"-members 8 have been located, cross "T"-members 10
are mechanically connected to the main "T"-members 8. There are a number
of different "T" bar grid systems, but these systems all work in a
similar manner. Although care is taken to accurately position the grid
network, some variation occurs, particularly with respect to the position
of the cross "T"-members 10.

[0042] The ceiling panels shown in the figures are referred to as lift and
shift ceiling panels. In this case, the particular securing mechanism
allows the panels to be shifted in one direction typically towards a main
"T"-member 8 and subsequently the panel is pivoted upwardly to the
horizontal position and shifted in the opposite direction to engage a
further "T"-member. Although the preferred arrangement is to support the
panel on the main "T"-members 8, it can be appreciated that support the
panel on the cross "T"-members 10 is also possible. There is a slight gap
between adjacent panels that is preferably kept to a minimum to hide the
"T" bar grid network

[0043] In contrast to existing lift and shift suspended ceiling systems,
the present ceiling panels include a wide outwardly extending flange
defining a wide border area about the ceiling panel. This aspect can be
appreciated from a review of FIG. 4, the perspective view of the ceiling
panel shown in FIG. 7, and the additional details shown in the partial
view of FIG. 8 showing a corner of the panel. This allows the flanges of
the panels to be immediately below the "T" bar grid with a portion of the
body of the panel above the bottom flange of the grid. The wide flange
provides the required space for the lift and shift installation.
Preferably, the wide flange is at least 1 cm wide and a flange with a
width between 1.5 cm and 2.0 cm is practical for many applications.

[0044] Each ceiling panel includes an outwardly extending perimeter flange
36 which is of a thin profile with the body of the ceiling panel
including the acoustical dampening material 40 located interior to this
flange. Preferably, this perimeter flange is defined by an extrusion
member 60 and the upper surface of the perimeter flange 36 includes a
securing channel 64 for receiving gusset clips 20. In this way the gusset
clips 20 are associated with the lower surface of the ceiling panel and
is only separated from this lower surface by the thickness of the
perimeter flange. A large portion of the ceiling panel including the
acoustical dampening material is located above the bottom flange of the
"T" bar grid support network as shown in the view of FIG. 9 and the
perspective views of FIGS. 4 and 11.

[0045] The large perimeter flange about the ceiling panel with the
inwardly offset acoustical dampening material allows for the lift and
shift installation of panels in combination with the perimeter flange,
gusset clips and "T" bar grid defining the finished level of the ceiling
panels.

[0046] FIGS. 14 and 15 show the extrusion member 60, preferably an
aluminum extruded member, that defines the perimeter flange of the
ceiling panels. This extrusion member is a miter cut to define the
corners of a rectangular panel. The extrusion member includes an
outwardly extending flange 62 that has a lower ribbed surface 63 used to
secure a finishing substrate 50 (see FIGS. 10 and 11) of the ceiling
panel. The finishing substrate 50 is adhered to the acoustical dampening
material 40 of a ceiling panel as well as the ribbed surface 63. The
extrusion member 60 includes the securing channel 64 on an upper surface
of the outwardly extending flange 62. The securing channel 64 includes
opposed side arms 66 and 68. This securing channel 64 receives first arm
26 and second arm 28 of each gusset clip 20. The securing channel 64 in
one embodiment includes one or more deformable shallow ridges extending
in the length of the channel to create a slight interference fit between
the securing channel 64 and the first and second arms of the gusset clip.
Alternatively, an adhesive can be used to secure the gusset clip arms in
the securing channel 64.

[0047] FIGS. 7, 8, 12 and 13 illustrate a finished ceiling panel 6 having
the perimeter flange 36 extending thereabout with gusset clips 20
engaging the abutting extrusion member at the corners of the panels.
Referring to FIG. 1, each gusset clip 20 is generally L-shaped and
defined by a first arm 26 and a second arm 28. The gusset clip 20
includes an upwardly and forwardly extending securing tab 22 with a
securing gap 24 provided below this securing tab and above the perimeter
frame 36 of the ceiling panel. The upwardly and forwardly extending
securing tab also includes a locating notch 30 that allows nesting of the
ceiling panels on the "T" bar support members in a predetermined position
aligned with the grid network. The second arm of the gusset clip includes
an aligning tab 32 at one end of the second arm, located outwardly of the
securing tab 22, to provide accurate positioning of the panel relative to
the T bar frame. Each rectangular panel has an aligning tab adjacent the
panel corners to align the panels with the cross "T"'s of the grid
system.

[0048] As shown in the perspective view of FIG. 16, the gusset clip 20,
and in particular the upwardly and forwardly extending securing tab 22,
is integral with the second arm. The gusset clip is preferably punched
from a metal sheet and the securing tab 22 bent upwardly. This accurately
locates the locating notch 30 relative to the corner of the finished
ceiling panel 6. The securing tab terminates slightly short of the
perimeter flange to allow over shifting relative to a "T"-member during
installation of the ceiling panel.

[0049] The extrusion member 60 includes vertical section 70 extending
upwardly from the outwardly extending flange 62 and this vertical section
acts as a frame about and in engagement with the acoustical material 40
of the ceiling panel. The vertical section 70 includes a top inwardly
directed flange 72 that overlies the top surface of the acoustical
dampening material 40 and an intermediate securing flange 74 that is
inserted into the acoustical dampening material. Depending upon the
particular acoustical dampening material, this intermediate securing
flange is preferably received in a slot of the dampening material and has
a slight interference fit therewith. Typically the securing flange
includes a ribbed surface and an adhesive can also be used to improve
securement.

[0050] As shown in FIG. 4, this extrusion member 60 defines the perimeter
edge of the ceiling panels and accurately defines the lower surface of
the ceiling panel. The gusset clips are received in the extrusion members
and accurately locate the upwardly and forwardly extending securing tabs
22 adjacent the corners of the panel. This particular structure of the
ceiling panel allows a large portion of the acoustical dampening material
to be positioned above the lower flange of the T bar, thus reducing the
distance between the lower flange of the T bar and the bottom edge of the
ceiling panel. The extrusion member also defines a border edge of the
acoustical dampening material 40 and serves to protect this material.

[0051] FIG. 4 and FIG. 16 show details of the gusset clip and also
illustrate how the position of aligning tab 32 has been bent upwardly
from the second arm and engages the edge of an alignment ridge 67
provided on the extrusion member. This engagement can be used to locate
the gusset clip relative to the corner of the panel. The opposite edge of
the aligning tab 32 also serves as an aligning surface for positioning of
the ceiling panel beneath the "T" bar grid network and acts like a
spacer. The aligning edge 34 abuts the cross bars of the T bar structure
acts like a spacer, controlling the alignment gaps between adjacent
panels.

[0052] A further benefit of the ceiling system is shown in FIG. 2 where
the perimeter flange of each ceiling panel is immediately below the grid
network and preferably the main "T"-members 8. This provides accurate
positioning of the ceiling panels beneath the grid members. The gusset
clips 20 are accurately secured on the extrusion member as opposed to a
top surface of the ceiling panel. This arrangement avoids additional
tolerance variations that can occur between the top surface of the
ceiling panel and the finished surface of the ceiling panel. With the
present arrangement, abutting ceiling panels are accurately located
beneath the "T" members and thus the junction between adjacent panels is
improved and the visual appeal of the ceiling is improved (less
variation).

[0053] The present system advantageously uses the "T" bar grid support
network that is widely available and relatively cost effective to use.
Improved accuracy of a lift and shift ceiling system is provided beneath
the "T" bar grid network by using extrusion members with a wide perimeter
flange about the ceiling panels. This perimeter flange is essentially
immediately below the lower flange of the "T" bar support network. The
securing of the ceiling panel beneath the "T" bar grid network is
achieved by using stamped gusset clips preferably that are received in
channels of the extrusion members. These gusset clips can only secure the
extrusion members about the body of the acoustical ceiling panel, but
they also accurately define the suspension points. A substantial portion
of the ceiling panel is above the lower flange of the "T" bar grid
network where tolerance variations in the thickness of the overall
ceiling panel are not transmitted to the finished surface.

[0054] The ceiling panels also include a wide perimeter flange about the
ceiling panels and this is defined by the extrusion members used to
define this edge. These extrusion members include an outwardly extending
flange which on the lower surface preferably includes a series of ribs.
These ribs are used to assist in the adhesive securement of a finishing
substrate while providing a transition between the acoustical dampening
material and the edge of the ceiling panels. This blends any variations
and hides the outer perimeter frame.

[0055] The modified gusset clip 120 of FIGS. 17 through 19 again includes
a first arm 126 and a second arm 128 that are received in extrusion
members 60 of the ceiling panels. In particular these arms are received
in the securing channel 64 on an upper surface of the extrusion member
60. In contrast to the gusset clip 20 the junction of the first arm 126
and the second arm 128 includes the securing tab 122 that is integral
with the second arm 128 and the securing tab 122 also includes the panel
aligning surface 132 and the panel guide surface 134 which is canted
relative to surface 132. The securing tab includes the end 123 that is
off set and inwardly positioned relative to the alignment surface 132. As
shown in FIG. 17 as well as the top view of FIG. 18 basically the end 123
is inwardly offset relative to the alignment surface 132 which is
inwardly spaced from the exterior edge of arm 128. Alignment surface 132
is positioned to engage and accurately position a panel relative to the
"T" bar flange. Guide surface 134 is inwardly angled to allow initial
positioning of the panel relative to the "T" bar flange and the securing
tab 122 is further inwardly offset and will provide the support on the
"T" bar flange.

[0056] The modified gusset clip 120 also includes the locating notch 30 on
the securing tab 122 and this does provide alignment and accurate
positioning beneath the "T" bar grid. As shown in FIG. 19 the modified
gusset clip 120 does allow for shifting of the panel to one side on the
"T" bar grid and then subsequent movement back to accurately locate the
panel via the locating notch 130. As shown in FIGS. 3, 4 and 5 the
opposite end of a panel will also include a similar clip but with an
opposite orientation. FIG. 20 illustrates a ceiling panel corner with the
modified gusset clip 120.

[0057] The modified gusset clip 120 of FIGS. 17 through 19 has effectively
combined the securing tab 22 of gusset clip 20 and the aligning tab 132
into a single tab that is bent from the second arm 128. The consolidation
of these functions in a single tab makes the gusset clip more cost
effective to manufacture.

[0058] A further feature of the modified gusset clip is the securing port
140. In some cases if a panel is used adjacent a wall or due to
particular circumstances it may be desirable to secure the panel by means
of the port 140. Typically this port is not used but there may be
circumstances where it is preferable to provide support through this
component.

[0059] Although various preferred embodiments of the present invention
have been described herein in detail, it will be appreciated by those
skilled in the art, that variations may be made thereto without departing
from the spirit of the invention or the scope of the appended claims.

Patent applications by Heikki Kolga, Maple CA

Patent applications by Martin Daniel Gerkes, Toronto CA

Patent applications by Ronald White, Holland Landing CA

Patent applications by DECOUSTICS LIMITED

Patent applications in class Element spaced from wall, ceiling, or floor and held by discrete retaining means (e.g., suspended ceiling or wall)

Patent applications in all subclasses Element spaced from wall, ceiling, or floor and held by discrete retaining means (e.g., suspended ceiling or wall)